Application of new tool material for electrical discharge machining (EDM)

In EDM, Cu and graphite are commonly used as tool materials. The poor wear resistance is the drawback of these tools. In the current study, an attempt has been made to develop a ZrB 2 -Cu composite as an EDM tool material to overcome this problem. Initially, the ZrB 2 powder is prepared by self-prop...

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Bibliographic Details
Published in:Bulletin of materials science 2009-08, Vol.32 (4), p.401-405
Main Authors: Khanra, A. K., Pathak, L. C., Godkhindi, M. M.
Format: Article
Language:English
Subjects:
Chemistry and Materials Science
Copper
Electric discharge machining
Engineering
Loose powder sintering
Low carbon steels
Machine tools
Materials Science
Particulate composites
Process parameters
Refractory materials
Self propagating high temperature synthesis
Sintering (powder metallurgy)
Surface roughness
Wear resistance
Zirconium compounds
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Summary:In EDM, Cu and graphite are commonly used as tool materials. The poor wear resistance is the drawback of these tools. In the current study, an attempt has been made to develop a ZrB 2 -Cu composite as an EDM tool material to overcome this problem. Initially, the ZrB 2 powder is prepared by self-propagating high-temperature synthesis (SHS) technique and synthesized powder is mixed with different amounts of Cu powder. Dense composite is developed by a pressureless sintering at 1250°C. The composites are tested as tool material at different EDM process parameters during machining of mild steel. The ZrB 2 -40 wt% Cu composite shows highest metal removal rate (MRR) with significant tool removal rate (TRR) than other composites. The performance of ZrB 2 -40 wt% Cu composite is compared to conventional Cu tool. The composite shows higher MRR with less TRR than Cu tool but it shows more average surface roughness and diameteral overcut than Cu tool.
ISSN:0250-4707
0973-7669
DOI:10.1007/s12034-009-0058-0